Papers by Keyword: Process Parameters

Abstract: This paper examines the evolution, processes, and optimization of Fused Deposition Modeling (FDM)/Fused Filament Fabrication (FFF) in additive manufacturing, synthesizing insights from existing literature on its mechanical properties and process parameters. Tracing its origins to rapid prototyping in the late 1980s, the paper highlights the advantages of FDM/FFF, such as cost-effectiveness and reduced material waste, while also addressing challenges like limited part strength. It consolidates knowledge on commonly used materials polylactic acid, acrylonitrile butadiene styrene, polycarbonate, and nylon through comparative analyses of their mechanical and thermophysical properties. The review critically assesses key process parameters, including raster angle, layer height, infill density, infill pattern, build orientation, printing speed, and nozzle diameter, drawing from diverse studies to explore their influence on part quality. Key findings include the potential of a 45°/-45° raster angle and a 0.2 mm layer height to enhance tensile strength, as well as the trade-offs associated with higher infill densities, which improve energy absorption but increase printing time. The paper identifies gaps in dimensional accuracy and material innovation, proposing future research directions to advance FDM/FFF applications across industries.

Abstract: Traditional sheet metal forming processes necessitate specialized tooling and costly dies to manufacture sheet metal components, leading to time-consuming and uneconomical procedures that are particularly unsuitable for batch production. However, Single Point Incremental Forming (SPIF) has emerged as a cost-effective solution for rapid prototyping, customization, and batch production. To achieve this, precise estimation of the incremental sheet forming force is essential, necessitating the design of dedicated equipment and the adaptation of machinery. This study explores the impact of several process parameters on the forces involved in SPIF to investigate their effects. Specifically, the focus is on analyzing the influence of step size, forming angle, and spindle speed on axial peak forces for Cp-Ti grade sheets. The results reveal that the maximum forming force increases with larger step downs, while a decrease in forming force is observed for smaller step sizes. Additionally, higher forming angles result in increased friction between the tool and the blank, leading to elevated forming temperatures. The evolution of forming force, which varies under different bending conditions, could serve as an indicator to prevent sheet failure. The current provides valuable insights into optimizing SPIF processes by understanding the relationship between process parameters and forming forces, facilitating more efficient and reliable production of sheet metal components.

Abstract: 15CDV6 steel is a high strength bainitic High Strength Low Alloy (HSLA) steel with low concentrations of chromium, molybdenum, and vanadium as the main alloying constituents. This steel is very robust and well-tempered i.e., it has High strength and good toughness. It is used in the manufacture of transformers, electric motors, nuclear reactors, and its application to the aerospace industry for the manufacture of rocket motor cases is immense. Simplifying any process of machining is very difficult, since it basically includes forecasts of machining parameters and working requirements that are unpredictable and extremely non-linear in nature which influence the overall production Quality and costs. A key component of producing novel products, particularly for the automotive and aerospace sectors, is wire electro discharge machining (Wire-EDM). This technology got success and offers unique advantages for specific applications, such as working with hard, super-tough, brittle, or difficult-to-machine materials, producing intricate shapes, or achieving high precision. The high degree of the obtainable accuracy and the fine surface quality makes Wire-EDM valuable. The right selection of the process parameters or input variables is the considered as most important task in Wire Electro Discharge Machining of 15CDV6 HSLA steel material. The present work concentrates on optimisation of various process parameters are Pulse-on Time, Pulse-off Time, Water pressure and sensitivity on work material 15CDV6 HSLA steel, the output responses considered are Material Removal Rate (MRR), Surface Roughness (Ra), and Power Consumption (PC). Taguchi Method technique used on experimental results for optimisation and same results are analysed using Analysis of Variance (ANOVA) for identify percentage contribution of process parameters. This work helps in analysing the suitable process parameters and machining performance for machining of 15CDV6 steel and also reveals the research work area in which maximum research work can be done in future.

Abstract: This paper presents a response surface methodology to fit a second-order response surface model aimed to finding process parameters to minimize length error (LE) and diameter error of the cylindrical shafts (DE) in fused deposition modeling (FDM) using polylactic acid (PLA) material. The process parameters in this study included layer height (LH), which varied from 0.1 to 0.4 mm, and print speed (PS), which ranged from 20 to 60 mm/s, while other parameters were set to constant values. The results showed that optimal process parameters obtained in this study significantly lower dimensional errors than the initial parameterization recommended by UltiMaker Cura software.

Abstract: The additive manufacturing technology called laser powder bed fusion enables to manufacture complex parts based on the fusion of a metallic powder layer by layer. In laser powder bed fusion, the produced component quality relies significantly on the parameters of the process. In this study, the powder titanium alloy Ti-6Al-4V is employed for the purpose of predicting the melt pool dimensions. To manufacture a single bead, several combinations of scan speed and laser power are used. This research studies the influence of the scan speed and the laser power on the melt pool dimensions and on the thermal history of a specified layer of powder. The results reveal that the geometry of the melt pool is considerably responsive to the scan speed and the laser power. Furthermore, unfavorable effects such as porosity defects are analyzed in detail. Suggestions are presented to employ optimal settings to prevent these undesirable outcomes. To validate the numerical results, a comparison with experimental results from the literature is carried out. Our numerical analysis proves a satisfactory correlation with the experimental investigations. The beam power and the scanning speed effects on the average temperature of the desired layers are discussed as well.

Abstract: The manufacturing industry has witnessed substantial interest in the advancement of 4D printing technology in recent years. This technology has enabled the production of complex structures with enhanced functionality and adaptability. Fused Deposition Modeling (FDM) has become a preferred technique for 4D printing due to its ease of use, affordability, and versatile nature. To achieve efficient and effective 4D printing, the process parameters must be optimised to ensure the desired shape recovery behaviour of the printed parts. The main objective of this study is to optimize the process parameters for the production of 4D printed components using FDM technology and Carbon Fiber reinforced Poly Lactic Acid (CF/PLA) Shape Memory Polymer Composites (SMPCs). This study examines the shape recovery properties of the printed components by modifying the process parameters, including Infill Density (ID), Geometrical Thickness (GT), and Bending Angle (BA), through the implementation of Design of Experiments (DOE) L9 Orthogonal Array (OA). Utilizing Analysis of Variance (ANOVA) to determine the significant factors and their optimum levels, the process parameters are statistically analysed. The results indicate that ID and GT are the statistically significant parameters, and the optimum levels for parameters includes 20% ID, 1.5mm GT, and 30⁰ BA led to faster shape recovery. This study demonstrates the effectiveness of the Taguchi approach in the design and optimization of the process parameters for 4D printed parts using FDM.

Abstract: Milling is a widely used machining process for creating intricate parts with desired dimensions and surface quality. In this study, we investigate the effects of process parameters namely spindle speed, feed rate and depth of cut on the vibration behavior of a milling machine tool. The analysis begins by selecting appropriate cutting conditions for the milling operation. Various combinations of process parameters are considered to observe their influence on vibration of the tool. A series of experiments are conducted, with each experiment using a specific set of process parameters. The experimental trials were designed according to the factorial design. Accelerometer is employed to capture the dynamic behavior of the tool and quantify the amplitude and frequency of vibrations. The results can be utilized to optimize the machining parameters for enhanced surface quality in milling operations, leading to improved productivity, reduced tool wear and increased overall process efficiency.

Abstract: Friction stir welding is a relatively new technique, which, due to its advantages, has been continuously developed and applied to industrial applications. Friction stir spot welds (FSSW) are one variant of friction stir welding (FSW) where the traverse part of the FSW process is eliminated, i.e., the tool is only plunged into the material and retracted. The resulting weld is a point or “spot” weld. This process of joining materials in solid state is an extremely complex one because of the physical phenomena that occur during the process, which makes the research still in full development. The paper presents an analysis of recent scientific work on the use of the FSSW process for the joining of steel structures. Thus, this study analyses the types of steel and joined structures, the process parameters used in experimental research, and the mechanical properties of FSSW joined steel structures. The main conclusions of the studied papers are summarized and the main research directions on the steel structures joined by the FSSW process are identified.

Abstract: Ni-based metallic amorphous alloys in ribbons shape are used in the manufacture of electrical resistances due to their high electrical resistivity, a value that does not change with temperature. The production of such resistances involves joining processes of amorphous ribbons. The amorphous alloys are difficult to weld by conventional melting processes, even in the presence of inert gas. Consequently, this paper presents the research carried out regarding the capacitor energy storage welding technique of Ni₆₃Cr₁₂Fe₄Si₈B₁₃ amorphous ribbons. The structural analysis was done by microscopy, X-ray diffraction, and differential scanning calorimetry, and the mechanical behavior was determined by nanoindentation. The joints obtained showed that the proposed welding technology is appropriate for this type of joint.

Abstract: In this study, the controlled input parameters namely welding speed and spindle speed were optimized by Taguchi method for reinforcement of copper particulates in aluminium alloy (AA6061-AA6063-T6). High carbon and high chromium steel i.e. tool steel D2 type material is used as a friction stir welding tool. Subsequently, the effects of the process parameters were investigated. The signal-to-noise ratios and analysis of variance were applied for statistical analysis. The outcome shows welding speed is the significant parameter than spindle speed. Under the optimum process parameters, 1400 rpm with 16 mm/min were shown best values such as 61.60 MPa for ultimate tensile strength and 91 hardness values. It means moderate spindle speed and lower welding speed develop higher heat. Subsequently, it is also shown that the feasibility of signal-to-noise ratio is responsible to improve welding quality after reinforcement.